Adjustable Draw-In Block Assembly for Closed-Loop Die Control
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Solution Overview
Problem
The stamping process often results in irregularities due to inconsistent material draw-in, leading to issues like splits, waves, slip lines, and wrinkles in stamped parts, as existing technologies fail to adequately control material draw-in during the forming process.
Innovation Solution
An adjustable block assembly is introduced in the stamp tool assembly, featuring interlocking teeth on top and lower plates that are inclined, allowing for precise adjustment of material draw-in by changing the spacing between draw-in surfaces, which is monitored and adjusted using sensors to maintain optimal draw-in levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material draw-in is insufficient during stamping, then the stamping process is simpler and faster, but splits and waves appear in the material
Solution Approach 1:
The patent changes the geometric parameters of the draw-in surfaces by providing multiple inclined surfaces with different angles and spacings. This allows adjustment of material draw-in parameters to optimize both production efficiency and part quality, preventing splits and waves through controlled material flow.
Solution Approach 2:
The patent makes the draw-in surface configuration dynamic and adjustable rather than fixed. By allowing selection among multiple inclined surfaces with different geometries, the system can adapt material draw-in characteristics to match specific blank shapes and stamping requirements, ensuring consistent quality across different production conditions.
2Manufacturing precision
If material draw-in is excessive during stamping, then more material flows into the die cavity, but slip lines and wrinkles form in the material
Solution Approach 1:
The patent provides multiple draw-in surface configurations with varying inclinations and spacings to control material flow parameters. By selecting appropriate surface geometries, excessive material draw-in is prevented while ensuring adequate cavity filling, thus avoiding slip lines and wrinkles.
Solution Approach 2:
The patent applies different draw-in surface geometries to different regions or conditions. By providing multiple inclined surfaces with specific angles and spacings tailored to particular blank shapes and stamping requirements, localized control over material flow is achieved, preventing defects in critical areas.
3Device complexity
If fixed draw-in surfaces are used in stamping, then the tool structure is simpler, but inconsistent material draw-in causes part irregularities
Solution Approach 1:
The patent introduces adjustability to the draw-in surface configuration while maintaining relatively simple tool structure. Multiple inclined surfaces can be selectively positioned or activated based on production requirements, providing consistent material draw-in control without significantly complicating the overall tool design.
Solution Approach 2:
The patent designs the draw-in surface assembly to serve multiple functions: it can accommodate different blank shapes, control material flow for various part geometries, and maintain consistent draw-in characteristics across production cycles. This multi-functionality is achieved through the array of inclined surfaces with different geometries.
Data Source
AI summary
A stamp tool assembly is provided that includes a forming cavity for shaping a blank into a formed part. The stamp tool assembly includes adjustable block assembly for modifying the amount of material draw-in from subsequently stamped blanks. A draw-in sensor measures the amount of material from the blanks that is not drawn-into the forming cavity during each stroke. Based on the readings from the draw-in sensor, the adjustable block assembly is expanded or reduced. The adjustable block assembly includes a pair of opposing inclined plates having interlocking teeth such that movement of one plate with respect to the other plate changes a vertical extension of the adjustable block assembly. The adjustable block assembly sets the spacing between two opposing draw-in surfaces, which, in turn, changes the amount of draw-in. Multiple adjustable block assemblies and draw-in sensors may be used in conjunction and controlled via a controlling system.